801763389 Mercruiser CONNECTOR

Troubleshooting
Troubleshooting can be difficult. On the pages that follow is a list of possible problems. To make a repair to a problem, make reference to the probable causes.This list of problems and probable causes will only give an indication of where a possible problem can be and what repairs are needed. Sometimes more or other repair work is needed beyond the recommendations in the list. Remember that a problem is not normally caused by one part, but by the relation of one part with other parts. This list cannot give all possible problems and probable causes. The service personnel must find the problem and its source, then make the necessary repairs.Fuel System Fault Diagnosis Chart Fuel Injector Fault Diagnosis Chart (On Engine) Fuel Injector Fault Diagnosis Chart (On A Nozzle Tester) HP - High Pressure; LP - Low Pressure; FI - Fuel InjectionRemove injectors: Always make sure that injectors are not damaged during removal as the valve tips can easily be damaged. Install Injectors: Make sure injector/cylinder head bore and seat are clean. See Testing And Adjusting for injector seal installation. If nozzle body or needle valve are worn or damaged, the nozzle and valve must be replaced.1. Engine Will Not Start2. Engine Starts, Runs For A Few Moments, Then Stops3. Engine Misfires Or Runs Rough4. Engine Runs Evenly But Loses Power5. Engine Does Not Have Enough Power6. Too Much Vibration7. Combustion Noise8. Valve Compartment Noise9. Oil In Cooling System10. Engine Knock11. Little Rocker Movement Arm And Too Much Valve Lash12. Valve Spring Lock Is Free13. Oil At The Exhaust14. Little Or No Valve Lash15. Engine Has Early Wear16. Coolant In Lubrication Oil17. Too Much Black Or Gray Smoke18. Too Much White Or Blue Smoke19. Engine Has Low Oil Pressure20. Engine Uses Too Much Lubrication Oil21. Engine Coolant Is Too Hot22. Exhaust Temperature Is Too High23. Starting Motor Does Not Turn Or Turns Too Slow24. Armature Turns, But Pinion Does Not Engage Flywheel Ring Gear25. With Starting Motor On, Pinion Engages Ring Gear, But Engine Does Not Crank (Flywheel Begins To Turn)26. Starting Motor Continues To Run After Ignition Switch Has Been Released27. Pinion Does Not Disengage After Engine Starts To Run28. Alternator Does Not Charge29. Alternator Charge Rate Is Low Or Not Regular30. Alternator Charges Too Much31. Alternator Is NoisyTroubleshooting Problems
Problem 1: Engine Will Not Start Probable Cause:1. Fuel Stop Control In NO FUEL Position Turn control to RUN position.2. Fuel Shutoff Solenoid Is Defective Replace solenoid.3. Fuel Tank Is Low, Air In Fuel System Fill fuel tank; bleed air from fuel system.4. Fuel Lift Pump Is Defective Remove lift pump; repair or replace as necessary.5. Fuel Filter, Water Separator Or Lines Are Restricted Check fuel supply line, filter and water separator.6. Fuel Injection Pump Operation Not Correct Repair or replace fuel injection pump.7. Injectors Are Defective Repair or replace injectors.8. Cold Start Heater Is Defective Check, replace if necessary.9. Valve Lash And/Or Pump Timing Not Correct Check, adjust if necessary.10. Weak Compression With weak compression, starting may be difficult in warm weather, but in cold weather the engine may refuse to start. The number of causes are great: worn liners, piston rings, leakage of valves, etc. Problem 2: Engine Starts, Runs For A few Moments Then Stops Probable Cause:1. Fuel Supply Line Or Filter Are Restricted Repair or replace as necessary.2. Fuel Lift Pump Operation Not Correct Check output of pump, repair or replace.3. Restriction In The Inlet Or Exhaust System Check and remove restrictions.4. Air In The Fuel System Find the air leak in the fuel system and correct it. Bleed the air from the fuel system. Problem 3: Engine Misfires Or Runs Rough Probable Cause:1. Fuel Pressure Is Low Make sure fuel tank has enough fuel. Look for leaks or bad bends in the fuel supply line. Check outlet pressure of the fuel lift pump. See Specifications.2. Air In The Fuel System Find the air leak in the fuel system and correct it. Bleed the air from the fuel system.3. Injector Is Defective Run engine at the rpm that gives maximum misfiring or rough running. Then, loosen a fuel line nut on the injection line for each cylinder, one at a time. Find the cylinder where loosening the fuel line nut does not change the way the engine runs. Test the fuel injector for that cylinder. Install new parts where needed.4. Valve Lash And/Or Pump Timing Not Correct Check, adjust if necessary.5. Fuel Injection Pump Operation Is Not Correct Repair or replace if necessary.6. Moisture In The Fuel System Locate, remove and install new clean fuel. Problem 4: Engine Runs Evenly But Loses Power Probable Cause:1. Injectors Need Repair Repair or replace as necessary.2. Fuel Injection Pump Operation Not Correct Repair or replace as necessary.3. Air Cleaner Restriction Clean or replace air cleaner.4. Fuel Injection Pump Timing Not Correct Check and make correction.5. Fuel Lift Pump Installed With Camshaft Lobe On Maximum Lift Install fuel lift pump with camshaft lobe on minimum lift and tighten bolts evenly.6. Loss Of Compression Engine needs repairs. Problem 5: Engine Does Not Have Enough Power Probable Cause:1. Low Quality Fuel Remove the fuel from the fuel tank. Install new filter element. Put a good grade of clean fuel in the fuel tank.2. Fuel Pressure Is Low Make sure there is fuel in the fuel tank. Look for leaks or bad bends in the fuel line between fuel tank and fuel lift pump. Look for air in the fuel system. Check outlet pressure of the fuel lift pump. See Specifications.3. Air In The Fuel System Refer to Problem 3.4. Accelerator Linkage Not Adjusted Properly Adjust linkage for full travel. Install new parts for those that are damaged or defective.5. Wrong Valve Lash Adjust according to Specifications.6. Fuel Injection Nozzle Is Defective Refer to Problem 3.7. Fuel Injection Pump Timing Not Correct Check and correct. Problem 6: Too Much Vibration Probable Cause:1. Loose Pulley Bolt(s) Tighten the bolt(s).2. Pulley Is Defective Install a new pulley.3. Engine Supports Are Loose, Worn